Vapor Recovery Process System

ABSTRACT

The present invention provides for a natural gas well vapor recovery processing system and method comprising recovering gaseous hydrocarbons to prevent their release into the atmosphere including providing a method for preventing the gaseous hydrocarbons from returning to a liquid state.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation-in-part application of U.S. patent applicationSer. No. 11/234,574, titled “Vapor Process System” filed Sep. 22, 2005,which claims the benefit of the filing of U.S. Provisional PatentApplication Ser. No. 60/612,278, entitled “Vapor Process System”, filedon Sep. 22, 2004, and the specifications and claims of thoseapplications are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention (Technical Field)

The present invention relates to vapor recovery processing systems foruse with natural gas wells. The invention comprises a pumping systemused with an engine instead of plunger lifts and can be used to removeevolved gases from hydrocarbon liquids to storage at or near atmosphericpressure.

2. Background Art

In addition to producing natural gas, many natural gas wells producehydrocarbon liquids and water. The liquids, hydrocarbons, and water areseparated from the flowing natural gas by a separator installed in theline carrying the flowing gas stream. The inline separator may operateat pressures as high as 1,500 psig or as low as 30 psig. The inlineseparator may separate the separated liquids into hydrocarbon and watercomponents. The separated water is dumped to disposal, and the separatedhydrocarbons are dumped to storage. The storage for the separatedhydrocarbons is generally a steel tank or tanks with each tank having acapacity of 200 to 500 barrels. The storage tanks may operate atpressures as high as 16 ounces to as low as atmospheric pressure.

An intermediate pressure separator is often used on natural gas wellsthat are operating at elevated pressures (150 to 1,500 psig). Theintermediate pressure separator may operate at pressures of 125 to 25psig. The intermediate pressure separator receives the total separatedliquid from the inline separator. The intermediate pressure separatorseparates the liquid into its components, hydrocarbons and water. Asdescribed above, the water is dumped to disposal and the hydrocarbonsare dumped to storage. As a result of the reduction of pressure, theintermediate pressure separator also releases most of the entrainednatural gas from the separated hydrocarbons. Without a means to recoverthe entrained natural gas or a means designed to collect and burn theentrained natural gas, the entrained natural gas released in theintermediate pressure separator will be vented to the atmosphere andwasted. In most systems designed to collect and burn the entrainednatural gas, the heat energy released by burning the natural gas iswasted to the atmosphere. A means is needed to prevent entrained naturalgas from being released to the atmosphere.

Because of the reduction in pressure from the intermediate pressureseparator to the storage tank, the liquid hydrocarbons dumped to thestorage tanks will release additional entrained natural gas, and anycomponent of the natural gas liquids that is not stable at the storagetank pressure and temperature will begin to evolve from the hydrocarbonliquids and change from a liquid to a gaseous state. The changing in thestorage tank of hydrocarbon liquids from a liquid to a gaseous state iscommonly referred to as “weathering”. Again, without a system to eitherrecover or burn the gases released from the hydrocarbon liquids dumpedto the storage tank, the gases will vent to the atmosphere and bewasted. The gases released from the storage tank are a high BTU value ofapproximately 3,000 BTU per cubic foot compared to the standard of 1,000BTU per cubic foot required for residential gas. A means is needed toprevent gases released from liquid hydrocarbons from being released tothe atmosphere.

For many years, systems have been made available to collect the gaseoushydrocarbons that are released from liquid hydrocarbons separated atelevated pressures and then transferred to storage tanks operating atnear atmospheric pressure. In addition to operating problems that canoccur with the currently available recovery systems, the biggest problemthat has limited their application has been capital cost, and thesystems have generally been applied to gas wells that have operated atpressures of 250 psig or less and that have produced volumes ofhydrocarbon liquids in the range of 100 barrels per day or more.

Natural gas wells that can produce 100 barrels per day or more ofhydrocarbon liquids do not generally require any type of artificial liftto lift the liquid hydrocarbons to the surface. In most cases, smallervolume natural gas wells do require artificial lift to lift the liquidhydrocarbons to the surface. A widely used artificial lift systems iscalled a “plunger lift”. The plunger is a metal device that falls to thebottom of the natural gas well tubing while the gas flow is shut off atthe surface. The plunger remains at the bottom of the tubing for aperiod of time while the gas well builds up enough pressure to provideenough gas flow to bring to the surface the plunger and the load ofliquid hydrocarbons the plunger is lifting. When the gas well is againopened, the plunger and liquid hydrocarbons rise to the surface. Often,the liquid hydrocarbons arrive at the surface as a slug that is muchlarger than the normal hydrocarbon liquid production of the well. Theliquid hydrocarbon slug can create a volume of flash and evolved gasesthat will overload the vapor recovery system.

On natural gas wells where the plunger lift or other types of artificiallift creates a slugging condition that overloads the vapor recoverysystem, a pumping system developed by Unico, Inc. (“Unico”) can be usedto lift the produced liquid hydrocarbons to the surface. Up until now,pumping of natural gas wells has been avoided because of pumpingproblems. Some of the problems with pumping gas wells have been gaslocking (a condition where the pumping barrel fills with gas and nofluid can be pumped), gas interference (a condition where the pumpingbarrel only partially fills with fluid each stroke of the pump), andfluid pounding (a condition where the downward stroke of the pumpcontacts the fluid in a less than fluid filled barrel). The Unicopumping system presents a solution to the problems of pumping gas wellsby only pumping the amount of fluids the well is producing. Pumping onlythe amount of fluids the well is producing prevents “pump-off” (acondition where the well bore is pumped dry thereby allowing gas toenter the pump barrel). A method is needed to eliminate gas entering thepump barrel to eliminate the problems associated with pumping naturalgas wells.

BRIEF SUMMARY OF THE INVENTION

An embodiment of the present invention provides for a natural gas wellvapor recovery processing system (referred to herein as “VRSA”) andmethod comprising recovering gaseous hydrocarbons to prevent theirrelease into the atmosphere including providing a method for preventingthe gaseous hydrocarbons from returning to a liquid state.

In one embodiment of the present invention, evolved gases are entrainedat the vacuum port of an eductor into a fluid stream and compressed. Thefluid flowing through the eductor discharges into an emissions separatorwhere the compressed gases separate from the fluid, and the compressedgases flow to the outlet of the emissions separator to be furtherprocessed while the fluid falls to the bottom of the emissionsseparator. The fluid collects in the bottom of the emissions separatorto provide a continuous closed circuit fluid feed to the suction of acirculating pump.

The emissions separator also receives entrained gas that evolves fromhydrocarbon liquids when the liquids are separated from a flowing gasstream at higher pressure and dumped to the lower pressure of anintermediate pressure separator. In the emissions separator, the twogases mix to form a homogeneous mixture. The homogeneous gas mixtureflows from the outlet of the emissions separator to the suction of a gascompressor where the gases are compressed to the pressure of the flowinggas stream. The compressed gases are discharged back into the flowinggas stream at the inlet to the inline separator where the compressedgases mix with the flowing gas stream to form, in the inline separator,a second homogeneous gaseous mixture. The second homogeneous gas mixtureflows from the outlet of the inline separator to other processing or topoints of sale.

Another embodiment provides for mixing a high BTU and vapor pressure gaswith a lower BTU and vapor pressure gas flowing in the pipeline toreduce the BTU and partial pressure of the compressed gas while at thesame time slightly raising the BTU and partial pressure of the flowinggas stream. Lowering the BTU and partial pressure of the compressedgases reduces the tendency of the gases evolved and recovered from thetank to return to a liquid state. Any of the compressed gases thatreturn back to a liquid state prior to passing out of the inlineseparator are again separated and dumped back to the storage tank.

Thus, an embodiment of the present invention provides a method forpreventing the release of natural gas in a natural gas well processingsystem from entering the atmosphere comprising, collecting evolved gasesfrom a storage tank, entraining the evolved gases into a fluid stream,compressing the evolved gases and fluid stream, sending the evolvedgases and fluid stream to an emissions separator, and separating thegases from the fluid for further processing. Preferably, the evolvedgases are collected using a vacuum, and preferably, the method furthercomprises providing an eductor to create the vacuum and to entrain thegasses into the liquid stream. The method preferably further comprisesmixing a first compressed gas with a second compressed gas flowing in apipeline, the second compressed gas having a BTU lower relative to theBTU of the first compressed gas to prevent gaseous hydrocarbons in thenatural gas well processing system from entering a liquid state.

Another embodiment provides a method for preventing the release ofgaseous hydrocarbons at a natural gas well processing system fromentering the atmosphere, the method comprising providing an emissionsseparator, sending to the emissions separator the entrained gases thatevolve form hydrocarbon liquids when the liquids are separated from aflowing gas stream at higher pressure and put in the lower pressure ofan intermediate separator, sending the gaseous hydrocarbons to acompressor and compressing the gaseous hydrocarbons, and sending thecompressed gaseous hydrocarbons to a flowing gas stream for furtherprocessing or point of sale.

Another embodiment provides a natural gas well processing systemcomprising a hydrocarbon storage tank, an eductor linked to the storagetank to receive gasses that evolve in the storage tank, entrain saidgasses into a fluid stream, and compress the gasses and said fluidstream, and an emissions separator linked to the eductor for receivingthe evolved gases and fluid stream for separation of the gasses from thefluid stream and for sending the gasses out of the emissions separatorfor further processing.

Other objects, advantages and novel features, and further scope ofapplicability of the present invention will be set forth in part in thedetailed description to follow, taken in conjunction with theaccompanying drawings, and in part will become apparent to those skilledin the art upon examination of the following, or may be learned bypractice of the invention. The objects and advantages of the inventionmay be realized and attained by means of the instrumentalities andcombinations pointed out in the appended claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a partof the specification, illustrate one or more embodiments of the presentinvention and, together with the description, serve to explain theprinciples of the invention. The drawings are only for the purpose ofillustrating one or more preferred embodiments of the invention and arenot to be construed as limiting the invention. In the drawings:

FIG. 1 is a flow diagram of an embodiment of the invention;

FIG. 2 is a flow diagram of a modification of the embodiment of FIG. 1;and

FIG. 3 is a schematic of a natural gas dehydrator system that may becombined with the embodiment of FIG. 1 or FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a vapor recovery processing system(referred to herein as “VRSA”) and method. An embodiment comprises apumping system to replace plunger lifts used on natural wells. Forexample, the pumping system such as that disclosed and marketed byUnico, Inc. (“Unico”) (or other appropriate) pumping system can be usedwith an engine such as that provided by Marathon Engine Systems (orother appropriate engine) to replace plunger lifts on natural gas wells.Replacing the plunger lift increases a well's production time byeliminating the lost production time associated with shutting down thewell to allow the plunger to fall to the bottom as well as eliminatingthe lost production time required for the well to build up enoughpressure to cause the plunger to rise to the surface. Often, the lostproduction time is greater than a well's production time. Besidesincreasing a well's production time, the Unico pumping system furtherincreases a well's production by lowering the pressure the producingformation is producing against. The fluids produced by the well arepumped up through the tubing, and the gas is produced out the casing,eliminating the pressure deferential between the casing and tubingrequired to produce both the fluids and gas up through the tubing.

An embodiment of the present invention provides an economical system foruse on natural gas wells that produce a small volume of hydrocarbonliquids (5 to 50 barrels per day), although the present invention canalso be used for larger volumes. The system collects and returns thegaseous hydrocarbons to a gas stream flowing at 250 psig or less, thegaseous hydrocarbons released as a result of separating liquidhydrocarbons from the flowing gas stream and transferring to, andstoring in, tanks, at near or atmospheric pressure, the separated liquidhydrocarbons.

In an embodiment of the present invention, an engine generator set suchas, for example, a 7.5 horsepower engine generator set (e.g. a generatorset such as supplied by Marathon Engine Company), is used to provide thepower to operate the gas recovery system. The engine generator setpowers electric motors (for example, two electric motors). One electricmotor powers a circulating pump to provide fluid energy to power aneductor that creates a vacuum to collect evolved gases from the storagetanks. The evolved gases are entrained at the vacuum port of the eductorinto the fluid stream and compressed to a maximum of, for example, 30psig. The fluid flowing through the eductor discharges into an emissionsseparator where the compressed gases separate from the fluid and thecompressed gases flow to the outlet of the emissions separator to befurther processed while the fluid falls to the bottom of the emissionsseparator. The fluid collects in the bottom of the emissions separatorto provide a continuous closed circuit fluid feed to the suction of acirculating pump.

The emissions separator also receives entrained gas that evolves fromhydrocarbon liquids when the liquids are separated from a flowing gasstream at higher pressure and dumped to the lower pressure of anintermediate pressure separator. On most installations, the intermediatepressure separator and the emissions separator operate at the samepressure (e.g. 30 psig or less), but on some installations it isdesirable to use a back pressure to hold the intermediate pressureseparator at a higher pressure than the operating pressure of theemissions separator. In the emissions separator, the two gases (one at,for example, approximately 3,000 BTU per cubic foot from the storagetanks and the other at, for example, approximately 2,000 BTU per cubicfoot from the intermediate pressure separator) mix to form, for example,an approximately 2,500 BTU per cubic foot homogeneous mixture. The 2,500BTU homogeneous gas mixture flows from the outlet of the emissionsseparator to the suction of a small capacity, conventional,reciprocating, gas compressor where the gases are compressed to thepressure of the flowing gas stream (e.g. 250 psig or less). Thecompressed gases are discharged back into the flowing gas stream at theinlet to the inline separator where the compressed gases mix with theflowing gas stream to form, in the inline separator, a secondhomogeneous gaseous mixture. The second homogeneous gas mixture flowsfrom the outlet of the inline separator to other processing or to pointsof sale.

Mixing the relatively small volume of high BTU and vapor pressure gas(e.g., approximately 2,500 BTU per cubic foot compressed gas) with thelarger volume of lower BTU and vapor pressure gas (e.g., approximately1,000 BTU per cubic foot gas) flowing in the pipeline greatly reducesthe BTU and partial pressure of the compressed gas while at the sametime slightly raising the BTU and partial pressure of the flowing gasstream. Lowering the BTU and partial pressure of the compressed gasesreduces the tendency of the gases evolved and recovered from the tank toreturn to a liquid state. Any of the compressed gases that return backto a liquid state prior to passing out of the inline separator are againseparated and dumped back to the storage tank. The physical process ofgases evolving from hydrocarbon liquids stored at low pressure, thegases being compressed to a higher pressure, then, after compression,the gases changing state from a gas back to a liquid, and, again, theliquid being dumped back to low pressure storage to begin evolving intoa gas again, greatly increases the compressor horsepower required torecover evolved gases. The higher the flowing line pressure, the moregases that will be evolved when hydrocarbon liquids are separated from aflowing gas stream and then dumped from the higher pressure to a lowerpressure Also, the higher the flowing line pressure, the greater is thetendency for the evolved gases from liquid hydrocarbons, dumped from ahigher pressure to a lower pressure, to change from a gaseous state backto a liquid state when the gases are collected and compressed back tothe higher pressure.

The tendency of hydrocarbon liquids to change state from liquids togases and then back to liquid again can create what are commonly called“recycle loops”. At times, the recycle loops can become large enough toforce the required compressor horsepower needed to recover the evolvedgases to become infinite and a simple vapor recovery system cannot beused. The “Hero” system described in U.S. Pat. No. 4,579,565, wasdesigned to address applications where simple vapor recovery was notpractical.

Another object of the present invention is to provide a process thatallows the use, with some modifications, of the previously describedcomponents of the simple vapor recovery system to collect the evolvedgases from hydrocarbon liquids separated at pressures as high as, forexample, 500 to 1,000 psig and then dumped to storage at, or near,atmospheric pressure. As previously described, without modifications tothe process, the simple vapor recovery system can develop, at highflowing gas pressures, recycle loops that could cause the horsepowerrequired by the recovery system to become infinite.

To decrease the tendency of gases evolved from hydrocarbon liquidsseparated at high pressure, dumped to storage at low pressure, collectedat low pressure, and then, again, compressed back to high pressure tochange state from a gas to a liquid, the previously described simplevapor recovery system is modified in the embodiment of the presentinvention described below.

In one embodiment, the collected volume of high BTU gas forming thesuction volume of any stage of the reciprocating compressor is increasedby as much as 5% to 10% by introducing lower BTU line gas from theinline separator into the volume of collected suction gas. Changing thepartial pressure of the homogenous gas mixture, by introducing lower BTUline gas into the higher BTU suction gas, decreases the tendency of thehigher BTU suction gas to change state from a gas to a liquid when thehomogenous gas mixture is compressed and cooled. In another embodiment,the temperature between stages of compression of the homogenous gasmixture is controlled to maintain the suction temperature of each stageof compression at approximately 100 to 120 degrees Fahrenheit. Bothembodiments can be combined in one system.

Turning now to the figures, FIG. 1 is a flow diagram of the vapor systemwhich accomplishes decreasing the tendency of the higher BTU suction gasto change state from a gas to a liquid. Referring to FIG. 1, line 3comprises a flowing natural gas stream. The flowing natural gas streamin line 3 enters inline separator 1 at inlet 2. While flowing throughinline separator 1, the free fluids, liquid hydrocarbons and water, areseparated from the flowing natural gas. The flowing natural gas exitsinline separator 1 at exit 5 and flows through line 4 to sales or otherprocessing.

The free fluids fall to the bottom of inline separator 1 and are dumpedthrough valve 6 (valve 6 is actuated by a liquid level control (notshown)) and flow through line 8 to enter intermediate pressure separator10 at inlet 12. The free fluids fall to the bottom of intermediateseparator 10. In the bottom of intermediate separator 10, the freefluids are separated by a conventional weir system into the free fluidscomponents, liquid hydrocarbons and water. The water is dumped by valve14 (valve 14 is actuated by a liquid level control (not shown)) andflows through line 16 to disposal. The liquid hydrocarbons are dumpedthrough valve 18 (valve 18 is actuated by a liquid level control (notshown)) and flow through line 20 to the inlet 22 of storage tank 24. Thechanges to the liquids being dumped from intermediate separator 10 tostorage tank 24 are described below.

The gas that flashes as a result of the liquid hydrocarbons being dumpedfrom the higher pressure of inline separator 1 to the lower pressure ofintermediate separator 10 form a first body of homogeneous gas mixturewhich comprises water vapor, portions of natural gas that were entrainedin the liquid hydrocarbons, and components of the liquid hydrocarbonswhich have flashed and have changed state from a liquid to a gas. Thefirst body of homogenous gas mixture exits intermediate pressure 10 atexit 26 and flows through line 28 to the inlet 30 of emissions separator32. The length of flow line 28 varies from location to location and inmost cases, but not always, it is installed above ground. During winter,line 28 may be exposed to low ambient temperatures which could cool thefirst body of homogenous gas mixture flowing in line 28 to a temperaturein which the gaseous liquid hydrocarbons and water vapor contained inthe first body of homogenous gas mixture could begin to change statefrom a gas to a liquid. It is desirable that none of the gases containedin the first body of homogeneous gas mixture change state from a gas toa liquid. The presence of any free water in flow line 28 as a result ofwater vapor condensing from the first body of homogeneous gas mixturewould pose a risk of ice forming in flow line 28 thus blocking the flowin line 28 of the first body of homogeneous gas mixture.

Several types of gas-to-gas heat exchangers can be used to provide heatto the first body of homogenous gas mixture flowing in line 28. Thegas-to-gas heat exchangers exchange the heat (e.g., between 225 and 300degrees Fahrenheit) contained in the hot discharge gas flowing in line36 with the first body of homogeneous gas mixture flowing in line 28thus raising the temperature of the gas flowing in line 28.

Both flow lines 28 and 36 may be field installed and connect the vaporprocessing system to the inlet of inline separator 1 and the outlet ofintermediate separator 10 which are in close proximity to each other.One type of heat exchange that may be used is to field lay lines 28 and36 so that they touch each other, and the two lines are may be insulatedwith heat resistant insulation. The heat of compression (e.g., 250 to300 degrees Fahrenheit) from flow line 36 provides heat along the entirelength of line 28 to substantially prevent some of the gases containedin the first body of homogenous gas mixture from changing state from agas to a liquid, and the heat from flow line 36 prevents freezing of anywater vapor that might condense in flow line 28.

The first body of homogenous gas mixture flowing in line 28 entersemissions separator 32 at inlet 30. Emissions separator 32 isapproximately half full of ethylene glycol (other appropriate liquids ormixture of liquids can also be used). The purpose of the body ofethylene glycol contained in emissions separator 32 is described below.The first body of homogeneous gas mixture entering emissions separator32 from intermediate pressure separator 10 mixes with the higher BTUfourth body of homogeneous gas mixture collected from the tanks andforms a second body of homogenous gas mixture (collection of the tankgases is described below). Any liquids that might condense from thecollected second body of homogeneous gas mixture will separate from thegas and be dumped through motor valve 46 (motor valve 46 is controlledby a liquid level controller (not shown)) and flow line 48 into storagetank 24. The collected second body of homogeneous gas mixture exitsemissions separator 32 at outlet 38. The collected second body ofhomogeneous gas mixture at approximately 27 psig flows through lines 41and 40 to the suction 42 of reciprocating compressor 34. Reciprocatingcompressor 34 compresses the collected gases up to a pressure range of,for example, approximately 125 to 250 psig. The discharge pressure ofreciprocating compressor 34 is determined by the pressure of the flowinggas stream contained in inline separator 1. From the discharge port 44of reciprocating compressor 34, the collected second body of homogeneousgas mixture flows through line 71 to point 72. At point 72, line 71divides to form lines 74 and 36. Line 74 terminates at pressureregulator 76. Pressure regulator 76 is set at approximately 27 psig tomaintain a near-to-constant suction pressure at suction port 42 ofreciprocating compressor 34. Compressor 34 is sized to compress more gasthan the volume of gas entering line 40 from emissions separator 32. Anytime the suction pressure at suction port 42 drops below the set pointof pressure regulator 76, gas flows from pressure regulator 76 throughline 78 to inlet 79 on emissions separator 32 to maintain anear-to-constant pressure at suction port 42. From point 72, thecollected second body of homogeneous gas mixture flows through line 36to point 142. From point 142, the second body of homogeneous gas mixtureflows through line 3 to the inlet 2 of inline separator 1. In inlineseparator 1, the collected higher BTU second body of homogeneous gasmixture from line 36 mixes with the larger volume lower BTU gasesflowing through inline separator 1 and forms a third body of homogeneousgas mixture.

Referring again to FIG. 1, and as previously described herein, theliquid hydrocarbons, from intermediate pressure separator 10 flowthrough motor valve 88 and line 20 and enter storage tank 24 at inlet22. The liquids from separator 10 flash to form a fourth body ofhomogenous gas mixture as a result of the pressure change from thepressure in intermediate separator 10 to the near or atmosphericpressure in storage tank 24. In addition to the immediate flash, theliquid hydrocarbons contained in tank 24 continue to evolve gases as theliquid hydrocarbons attempt to reach equilibrium with the gasescontained in tank 24. The fourth body of homogenous gas mixture of flashand evolved gases exit storage tank 24 at outlet 50. The fourth body ofhomogeneous gas mixture from storage tank 24 flows through lines 51,back pressure regulator 53, line 52, line 55, and line 57 to the vacuuminlet 54 of eductor 56.

Eductor 56 is powered by ethylene glycol or other appropriate fluid thatis pumped from emissions separator 32 by circulation pump 58. Theethylene glycol exits emissions separator 32 at fluid outlet 60. Theethylene glycol (at, for example, approximately 27 psig) flows throughline 64 to suction inlet 62 of circulation pump 58. Circulation pump 58increases the pressure of the ethylene glycol to approximately 120 psig.The pressurized ethylene glycol exits circulation pump 58 at dischargeport 66 and flows through line 68 to power port 61 of eductor 56. Whileflowing through eductor 56, the pressurized ethylene glycol powerseductor 56 to create a vacuum at vacuum port 54. The vacuum generated byeductor 56 is controlled to a few inches of water column (e.g., 3 to 12inches) by a vacuum controller such as, for example, a model 12 PDSCsupplied by Kimray, Inc. Vacuum controller 82 is connected to line 52 atpoint 81. Vacuum controller 82 outputs a throttling pressure signal tonormally opened motor valve 88. Normally opened motor valve 88 isinstalled at the termination of line 86. Line 86 begins at point 84 atthe end of line 41 and terminates at the inlet of normally opened motorvalve 88. Normally opened motor valve 88 is connected by line 90 to line55 at point 92. When the vacuum at point 81 exceeds the set point ofvacuum controller 82, vacuum controller 82 decreases the output pressureto normally open motor valve 88. The decrease of output pressure tonormally opened motor valve 88 causes normally opened motor valve 88 topartially open thereby increasing the flow of gas from emissionsseparator 32 through line 86, motor valve 88, and line 90 into line 55.Increasing or decreasing the volume of gas flowing from emissionsseparator 32 to vacuum port 54 of eductor 56 maintains the desiredvacuum in line 52.

The fourth body of homogeneous gas mixture from storage tank 24 is drawninto eductor 56 through line 51, back-pressure regulator 53, line 52,line 55, and line 57 by the vacuum created by eductor 56. To prevent airentering the system, back-pressure regulator 53 holds a positivepressure of approximately 8 ounces on tank 24. The collected fourth bodyof homogenous gas mixture is drawn into eductor 56 through vacuum port54 and is entrained into the flowing ethylene glycol and compressed to apressure of, for example, approximately 27 psig contained in emissionsseparator 32. The ethylene glycol and the entrained and compressedfourth body of homogenous gas mixture exit eductor 56 at port 68 andflow through line 70 to inlet 72 of emissions separator 32. In emissionsseparator 32, as previously described, the collected fourth body ofhomogenous gas mixture from storage tank 24 mixes with the first body ofhomogenous gas mixture from intermediate pressure separator 10 and formsa second body of homogeneous gas mixture. The ethylene glycol separatesfrom the entrained gases and falls toward the bottom of emissionsseparator 32. The ethylene glycol discharged by eductor 56 joins thebody of ethylene glycol contained in the approximate bottom two-thirdsof emissions separator 32. The ethylene glycol is continuouslycirculated in a closed loop by circulation pump 62 to provide power toeductor 56.

Heat is generated by the pumping of the ethylene glycol as well as thecompression of the collected gases. It is desirable to control thetemperature of the ethylene glycol to, for example, betweenapproximately 100 and 120 degrees Fahrenheit. Forced draft cooler 101provides cooling for the ethylene glycol. Forced draft cooler 101 isconnected to circulating pump 58 discharge line 68 at point 94. Line 96,hand valve 98, line 97, thermostatically controlled mixing valve 102,and line 100 connect inlet 99 of forced draft cooler 101 to point 94.Outlet 103 of forced draft cooler 101 is connected by line 105 and line104 to emissions separator 32 at point 106.

A side stream of ethylene glycol under pressure from circulating pump 58flows through forced draft cooler 101 and returns to emissions separator32 thus cooling the ethylene glycol. The volume of ethylene glycol(e.g., 3 to 6 gallons per minute) flowing in the side stream iscontrolled by adjusting hand valve 98. To maintain the desiredtemperature of the ethylene glycol of between 100 and 120 degreesFahrenheit, thermostatically controlled mixing valve 102 can bypassthrough line 107 a part of, or the entire side stream of, ethyleneglycol. Whenever the ethylene glycol becomes too cold, thermostaticallycontrolled mixing valve 102 reduces the volume of the side streamflowing through forced draft cooler 101.

FIG. 2 is a flow diagram of the embodiment wherein the temperaturebetween stages of compression of the homogenous gas mixture iscontrolled to maintain the suction temperature of each stage ofcompression. As noted above, the embodiment shown in FIG. 2 is intendedfor applications where the flowing gas pressure is elevated to pressuresabove, for example, 250 psig and where the changing of liquidhydrocarbon vapors back from a gas to a liquid state creates recycleloops.

All of the components described in FIG. 1 are incorporated into FIG. 2and only the components of FIG. 1 required to explain the modificationsshown in FIG. 2 are described detail below.

As shown in FIG. 2, a third stage of compressor 110 is added to receivethe discharge gas from second stage compressor 34. The hot (e.g., 225 to300 degrees Fahrenheit), compressed, and collected second body ofhomogeneous gas mixture exits compressor 34 at discharge port 44 andflows to point 72. From point 72, the hot, compressed, and collectedsecond body of homogeneous gas mixture flows through line 36 to point112 where a side stream of sales gas from inline separator 1 enters line36 and mixes with the hot, compressed, collected second body ofhomogenous gas mixture forming a fifth body of homogeneous gas mixture.The volume of gas from inline separator 1 that enters line 36 at point112 increases the total volume of gas passing through point 112 byapproximately 5% to 10%. The side stream of gas flows from inlineseparator 1 through line 4 to point 114. From point 114, the side streamof gas flows through line 116, flow meter 118, line 120, flow controlvalve 122, and line 124 to point 112. Flow control valve 122 iscontrolled by a PLC or other flow control device (not shown) to allowthe required volume of side stream gas from inline separator 1 toincrease the volume of gas flowing through point 112 by, for example,approximately 5% to 10%.

As described above, mixing a lower BTU and vapor pressure gas with ahigher BTU and vapor pressure gas reduces the tendency of some of thecomponents of the higher BTU gas to change state from a gas to a liquidthereby reducing the chance of recycle loops forming.

From point 112, the fifth body of hot homogeneous gas mixture flowsthrough line 127 to inlet 128 of forced draft cooler 133. While flowingthrough forced draft cooler 133 the gases are cooled to an approximately20 degrees Fahrenheit approach to ambient temperature. The cooled gasesexit forced draft cooler 133 at outlet 130 and flow through line 132 tocool gas inlet port 125 of thermostatic bypass valve 126. Thermostaticbypass valve 126 monitors the temperature of the gas flowing out ofoutlet 129 into line 134. When the gas temperature exiting outlet port129 of thermostatic bypass valve 126 drops to approximately 120 degreesFahrenheit, thermostatic bypass valve 126 begins to bypass some of thehot gas around cooler 133. The hot gas flows from point 135 throughbypass line 131 to hot gas inlet port 139 of thermostatic bypass valve126. The hot gas from hot gas inlet port 139 mixes in thermostaticbypass valve 126 with the cooled gas from cool gas inlet port 125thereby maintaining the gas temperature in line 134 at approximately 120degrees Fahrenheit. Keeping the gas in line 134 at approximately 120degrees Fahrenheit prevents most of the liquid hydrocarbon condensationthat might occur at a cooler temperature in line 134 or separator 146.

The approximately 120 degrees Fahrenheit temperature fifth body ofhomogeneous gas mixture enters separator 146 at inlet 148. Separator 146removes any liquids that may have resulted from a phase change from agas to liquid after the fifth body of homogenous gas mixture iscompressed and cooled. The liquids separated in separator 146 are dumpedby motor valve 150 (motor valve 150 is actuated by a liquid levelcontroller not shown) through lines 152 and 154 into intermediatepressure separator 10. As described above, some of the gases and liquidscontained in the liquid from separator 146 will flash. The balance ofthe liquids from separator 146 will drop to the bottom of intermediatepressure separator 10 and mix with the liquids from inline separator 1.The overall operation of intermediate separator 10 has been describedabove.

The fifth body of homogenous gas mixture in separator 146 exits atoutlet 156 of separator 146 and flows through line 158 to enter thirdstage compressor 110 at suction port 136. Third stage compressor 110compresses the fifth body of homogenous gas mixture to the pressure ofthe flowing gas stream. From discharge port 139 of third stagecompressor 110, the gas flows through line 140 (as previously described,line 140 is installed to be in heat exchange relationship with line 28from intermediate pressure separator 10) to point 142. At point 142, thefifth body of homogenous gas mixture enters line 3 and mixes with theflowing gas stream to form, in inline separator 1, the previouslydescribed third body of homogeneous gas mixture. The function of inlineseparator 1, as well as the function of the rest of the process, hasbeen described above.

The embodiments described herein have been shown utilizing only threestages of compression (the eductor and two stages of compression).However, it should be understood that other embodiments of the presentinvention can incorporate more than three stages of compression. Also,it should be understood that mixing gases of different BTU's in relationto each other (i.e., a lower BTU gas with a higher BTU gas such as alower molecular gas such as methane with a higher molecular weight gassuch as butane) can be done between any stage of compression (or at anypoint in the system). Thus, such a mixing of gases can be performedbetween the first and second stages and/or between the second and thirdstages of compression shown in FIG. 2.

There is the potential in cold climates of gas hydrates forming involume control valve 122 and motor valve 150 (hydrates are an ice-likesubstance that can form from natural gas when the proper temperature,pressure, and water content are present). Where needed, the potential ofhydrates forming in the system can be eliminated by installing agas-to-gas heat exchanger upstream of volume control valve 122 and agas-to-liquid heat exchanger upstream of motor valve 150. The hot gasfor both exchangers can be the hot discharge gas from compressor 34.

In another embodiment of the present invention, the Vapor RecoveryProcess System (“VRSA”) described above is combined with natural gasdehydrations systems and methods such as that described in U.S. Pat. No.6,984,257, titled “Natural Gas Dehydrator and System” (to the inventorherein), the specification and claims of which are incorporated hereinby reference, and which are referred to herein as “QLT”,to provide acombination QLT/VRSA unit. FIG. 3 shows such a natural gas dehydrationsystem (“QLT”) that may be combined with the VRSA. By combining the twotechnologies into a common unit, many of the features, which havecommonality in both technologies, are used to reduce the manufacturingcosts of a combination QLT/VRSA unit as well as reducing installationand operating costs. The combination QLT/VRSA unit further comprisesimprovements that enhance the performance of both technologies. Althoughthe description that follows is illustrative of a retrofit unit, thecombination QLT/VRSA unit could also be provided in combination with anatural gas dehydrator.

Preferably, most of the operating features/components of the QLT andVRSA would be utilized in the combination QLT/VRSA unit. Because themajority of applications for the combination QLT/VRSA unit are at anon-electrified well sites, the following description is of a well siteapplication where commercial electricity is not available, although thepresent invention is applicable to well sites having electric service.

Non-electrified well sites require either an engine generator to provideelectric power to run the pumps and compressor required to operate theQLT and VRSA or else the pumps and compressor can be direct belt drivenfrom a common shaft powered by an engine. Because of the possibleexplosive factor present when using electricity, direct driving thepumps and compressor is a better choice for non-electrified well siteapplications of the QLT and VRSA.

Some of the commonality that exists between the QLT and VRSA areobvious. Both technologies use a natural gas fueled engine to provideunit operating power. In the combination QLT/VRSA unit, only one engineis required. Both technologies use eductors to create a vacuum andcompress collected vapors. Both technologies utilize a high volumecirculating pump to circulate glycol to provide the energy to power theeductor. In the combination QLT/VRSA unit, only one high volumecirculating pump is required. Both units require a house and skid. Bothunits require an emissions separator. In the combination QLT/VRSA unit,only one emissions separator is used to receive the rich glycol from thedehydrator absorber. The rich glycol from the dehydrator absorber iscirculated by a high volume pump through two eductors, one for the VRSAand one for the QLT. Using the rich glycol from the dehydrator absorberto power the VRSA eductor eliminates the necessity for providing glycolfor the original glycol fill of the VRSA emissions separator, eliminatesthe need for heating the glycol in the VRSA emissions separator,eliminates the concern for ever having to replenish the glycol in theVRSA emissions separator, and eliminates any concern that the glycol inthe VRSA emissions separator would ever become saturated with water orhydrocarbons. Other commonalities and improved process functions willbecome apparent as the design and operation of the combination QLTNRSAunit is further described below.

As noted above, an embodiment provides that two eductors be used in thecombination unit. One eductor is used to provide the vacuum to collectand compress the vapors from the gas well's or wells' fluid production,and the other eductor is used to provide the vacuum to collect andcompress the emissions from the dehydrator or dehydrators located at thewell site.

Two eductors allow both the VRSA and QLT to be operated at the mostdesirable vacuum for the process. Because a back-pressure regulator isused in the VRSA system to hold a minimum of 4 ounces on the storagetank, the vacuum on the VRSA system is operated at a higher level thanthe vacuum on the QLT system. On most dehydrators that would beretrofitted with the QLT, the reboiler operates at atmospheric pressure,and any vacuum applied to the reboiler raises the glycol level in thereboiler. The specific gravity of glycol compared to water isapproximately 1.1; therefore, each one inch water column vacuum raisesthe glycol level in the reboiler approximately 0.9 inches. Reboilers aregenerally designed to operate substantially full of glycol, and anyexcess or uncontrolled vacuum can cause glycol overfill conditions inthe reboiler. The QLT is designed to operate at 2 to 3 inches watercolumn vacuum.

Using two eductors in the combination unit requires that two vacuumseparators be used —one for the VRSA and one for the QLT. The vacuumseparator for the VRSA is two-phased—the first phase is uncondensedhydrocarbon vapors, and the second phase is condensed hydrocarbonliquids. The uncondensed hydrocarbon vapors under a vacuum in the VRSAvacuum separator are pulled into the VRSA eductor and compressed into acommon emissions separator. The condensed hydrocarbon liquids under avacuum are collected in the bottom of the VRSA vacuum separator anddumped back to the storage tanks. It should be again noted that the VRSAeductor is powered by rich glycol generated by the dehydration process.The vacuum separator for the QLT is a three-phased and operates the sameas the three-phased vacuum separator previously described in, forexample, U.S. Pat. No. 6,984,257, and the QLT eductor also operates thesame as described in, for example, U.S. Pat. No. 6,984,257. Theuncondensed hydrocarbon vapors from the QLT vacuum separator arecollected and compressed into the common emissions separator to form ahomogeneous mixture with the hydrocarbons collected from the VRSA vacuumseparator.

Sizing of the VRSA eductor is complicated by the fact that hydrocarbonliquid production from gas wells is seldom constant. Generally, thevolume of liquid hydrocarbons flowing to the storage tanks is erratic,and many times the volume of liquid hydrocarbons flowing to the storagetanks is produced in slugs. Because the production of liquidhydrocarbons from gas wells is seldom constant, the hydrocarbon vaporload on the combination VRSA eductor is constantly changing, andsometimes the hydrocarbon vapor load can, and will, overload thecapacity of the VRSA eductor.

Sizing of the QLT eductor is not as complicated as the sizing for theVRSA eductor. On a dehydrator, the glycol circulation rate is fairlyconstant, and other conditions, such as gas temperature or changes indehydrator operating pressure do not generally occur rapidly or of amagnitude to significantly affect the uncondensed vapor load on the QLTeductor. In all cases, the QLT eductor is sized to have excess capacityto handle any expected uncondensed vapor load that might occur from thedehydration process. In the combination unit, any available excesscapacity of the QLT eductor can be utilized to increase the capacity ofthe VRSA eductor. An overload condition of the VRSA eductor occurs whenthe VRSA vacuum separator experiences a positive pressure conditionapproaching the 4 ounce positive pressure setting of the tank vent lineback-pressure regulator. As the positive pressure in the VRSA vacuumseparator approaches 4 ounces, a valve in a line between the VRSA andQLT vacuum separators opens thus allowing excess uncondensed hydrocarbonvapors in the VRSA vacuum separator to begin flowing into the QLT vacuumseparator. The volume of uncondensed hydrocarbon vapors flowing from theVRSA to the QLT vacuum separator is controlled so that the total volumeof uncondensed hydrocarbon vapors entering the QLT vacuum separator doesnot exceed the capacity of the QLT eductor.

Combining the VRSA technology into other production equipment such as aproduction unit, a standard dehydrator, or a QLT equipped dehydratorcreates a potential well site installation problem. Because of safetyconcerns, the liquid hydrocarbon storage tanks are located on the wellsite at a considerable distance (100 to 200 ft) from any piece of wellsite production equipment that is direct fired. Ordinarily, the VRSA isinstalled in close proximity to the storage tanks. By installing theVRSA close to the storage tanks, the tanks' vent line can be sloped fromthe top of the tank to the inlet connection on the VRSA. Sloping thetanks' vent line prevents any condensed hydrocarbon liquids fromcollecting in the tanks' vent line and creating a liquid seal to blockthe flow of the hydrocarbon vapors from the tanks to the VRSA.

Because the retrofit combination QLT/VRSA unit is installed in closeproximity to the well site direct fired dehydrator, the VRSA portion ofthe combined unit is located a considerable distance from the liquidhydrocarbon storage tanks. It would be impractical and costly to suspendin the air the tanks' vent line from the top of the tanks to the VRSAinlet of the combination unit. Therefore, connecting the combinationVRSA inlet to the top of the storage tanks is preferably by goingdirectly down from the top of the tanks to below ground level andrunning the vent line underground to connect from underground into theinlet of the combination VRSA.

Running the storage tanks' vent line underground from the tanks to theVRSA solves all the problems with the tank vent line except for theproblem of creating a condensed liquid trap which would form a liquidseal to stop the flow of vapors from the storage tanks to the VRSA. Toeliminate the fluid trap, the following is installed as part of thecombination unit. A vertical fluid collection pot, preferablyapproximately two feet long and four inches in diameter, is installedunderground where the tank vent line ends and the bottom of a preferablyvertical two inch diameter riser pipe connected to the VRSA inletbegins. The VRSA inlet includes the back-pressure regulator thatmaintains a positive pressure (approximately 4 ounces) on the storagetanks. The vertical riser pipe connects to the VRSA inlet upstream ofthe back-pressure regulator. The tanks' vent line is installed so thatthere is a gradual slope from the tanks to the VRSA unit. The tank ventline, generally an approximately two inch diameter pipe, connects to theside near the top of the vertical fluid collection pot. The bottom ofthe vertical riser pipe connected to the VRSA inlet connects to the topof the vertical fluid collection pot. A ½ inch diameter pipe isinstalled inside the two inch vertical riser pipe which is connectedbetween the top of the fluid collection pot and the VRSA inlet. Thebottom end of the ½ inch diameter pipe terminates approximately 1 inchabove the bottom of the fluid collection pot. The top of the ½ pipeturns horizontal and exits the vertical two inch riser pipe through theside approximately one foot below where the vertical two inch riser pipeconnects to the VRSA inlet. The horizontal top outlet of the ½ inch pipeconnects to the vacuum port of a ½ inch eductor such as a Penberthymodel 1/2 ALH. A side stream of rich glycol (approximately 2gallons/minute) from the common emissions separator circulates underpressure from the circulation pump of the combination unit to the powerport of the ½ inch eductor. The outlet of the ½ inch eductor connects tothe common emissions separator at approximately the same level as theconnections for the QLT and VRSA eductors.

In operation, hydrocarbon liquids condensed from the vapors collect inthe tanks' sloped vent line and flow along the bottom of the sloped ventline into the vertical fluid collection pot. The ½ inch eductorcontinually lifts the condensed hydrocarbon liquids through the ½ inchline inside the riser pipe and sends the condensed hydrocarbon liquidsunder pressure into the common emissions separator. The common emissionsseparator collects the condensed hydrocarbon liquids and dumps them backto the storage tanks. During those times when the capacity of the ½ incheductor is not being required to lift condensed hydrocarbon liquids, the½ eductor slightly increases the vacuum capacity (approximately 16 cubicfeet per hour) of the VRSA.

As noted above, the vertical riser pipe connected to the top of thefluid collection pot is connected to the VRSA inlet upstream of the tankvent line back-pressure valve. Because the ½ inch eductor is liftingfluids and possibly pulling a vacuum on the tanks vent line upstream ofthe vent line back-pressure valve, under conditions of no or littlefluid production to the tanks, the ½ eductor could lower the positivepressure on the tanks and possibly create a vacuum on the tanks. Toprevent any possibility that the ½ inch eductor could create a vacuumcondition on the tanks an ounces regulator is installed in a linerunning between the common emissions separator and the vertical riserpipe. The inlet of the line containing the ounces regulator is connectedto the common emissions separator in the vapor chamber close to the top.The outlet of the line containing the ounces regulator is connected tothe riser pipe upstream of the vent line back-pressure regulator.

In operation, the ounces regulator is set to maintain a pressure in thetanks' vent line slightly less then the pressure setting of the ventline back-pressure regulator. As long as the pressure on the vent lineis above the setting of the ounces regulator, no vapors feed from theemissions separator into the tanks vent line; however, if conditionsever exist where a vacuum induced by the ½ inch eductor lowers thepressure in the tanks vent line enough to reach the set pressure of theounces regulator, the ounces regulator would feed hydrocarbon vaporsfrom the common emissions separator into the tanks' vent line tomaintain a positive vent line pressure equal to the ounces regulatorsetting. By using collected vapors from the common emissions separatorto maintain the positive pressure on the tanks' vent line, no additionalhydrocarbon vapors are introduced into the system.

It should be noted that the fluid pumping system described above may beused on any type of unit where the VRSA technology is combined with apiece of equipment that requires the combined unit to be installed adistance from the hydrocarbon storage tanks. On stand alone VRSA unitswhere the tank vent line can be installed allowing the line to be slopedfrom the top of the tank to the VRSA inlet, the fluid pumping system isnot required.

The application of the stand alone VRSA as well as combination unitsdesigned to utilize the VRSA technology will be increased by the move,on shore, to directionally drill multiple gas wells from a common wellpad. Having multiple gas wells producing from a common well padincreases the volume of recovered hydrocarbon liquids at the well padwhich, in turn, improves the economics of installing a VRSA. Theeconomics of installing a VRSA on multiple gas wells are improvedbecause one VRSA can be utilized to recover the venting from all thehydrocarbon storage tanks located on the well pad. It follows that theeconomics of installing, on a multiple well pad, a QLT or a combinationQLT/VRSA unit would be improved by designing the QLT or combinationQLT/VRSA unit so that one QLT unit can be utilized to collect all theventing that occurs from multiple dehydrators on the well pad.

Thus, in an embodiment, one combination QLT/VRSA unit is used to collectall the hydrocarbons that are vented to the atmosphere by multipledehydrators and multiple hydrocarbon storage tanks located on one wellpad. The one combination QLTNRSA unit turns the well pad into anemissions free location with all recovered hydrocarbons either beingused for fuel gas or sold to produce increased revenues. As previouslynoted, no design change or concept is required for one VRSA to collectthe storage tank vapors from multiple wells on a common well pad. TheQLT requires some minor design and conceptual changes for one QLT torecover the hydrocarbon venting from multiple dehydrators on a well pad.

On a multiple well pad with no commercial electricity, “one” dehydratoron the multiple well pad would operate with a natural gas fueled enginedirect driving the circulation pump and positive displacement pumpneeded to power the VRSA and all other dehydrators. The balance of theQLT system on the “one” dehydrator would be larger. Each additionaldehydrator on the well pad operates as follows. To eliminate the gaswhich is normally vented by, for example, a Kimray glycol pump, theKimray glycol pump is powered by rich glycol from the emissionsseparator which is part of the QLT system for the “one” dehydrator. Therich glycol is pressurized by a positive displacement pump to a pressureadequate to power the Kimray pumps on the additional dehydrators. One ormore positive displacement pumps are used to provide the pressurizedrich glycol required to run the additional Kimray glycol pumps. Afterproviding power to run the additional Kimray glycol pumps, the richglycol is returned to the emissions separator which is part of the “one”dehydrator QLT system. It should be noted that on some applications ofthe combination QLTNRSA unit, depending upon the absorbers operatingpressure, it is possible to operate the Kimray glycol pumps the way theyare designed to be used (using the rich glycol exiting the absorbers topower the pumps). If the application should allow the Kimray glycolpumps to be powered by the rich glycol exiting the absorber, the excessgas generated by the Kimray glycol pumps would be routed to the firststage of the VRSA gas compressor to be compressed to sales pressurealong with collected vapors.

On all additional dehydrators on a common well pad where the Kimraypumps are being driven with rich glycol with the energy being suppliedby a direct driven positive displacement pump, a dump pot must beinstalled, and, if a three-phased flash separator is not already on thedehydrator skid, in the preferred design, a three-phased flash separatormust be installed. The dump pot is necessary for the process tofunction. The three-phased flash separator is preferably, but notabsolutely necessary, for the process to function. In the preferreddesign, the dump pot receives the rich glycol from the absorber anddumps the rich glycol to a flash separator. The flash separator operatesat a pressure higher then the first stage of the VRSA gas compressor.When the pressure in the three-phased flash separator reaches thepressure set point, uncondensed gases released from the rich glycolexiting the absorber flow to the first stage of the VRSA gas compressorto be compressed to sales pressure along with collected vapors. Anyliquid hydrocarbons in the rich glycol exiting the absorber arecollected in the three-phased flash separator and dumped to thehydrocarbon storage tanks. As in the normal dehydration process andbefore the dump pot is installed, the rich glycol entering thethree-phased flash separator from the absorber is dumped from thethree-phased flash separator to flow through the same glycol path astaken by the rich glycol when the rich glycol exited the Kimray glycolpump after being used to drive the pump.

The still column effluents from each additional dehydrator on a well padare collected by connecting the still columns of each additionaldehydrator to the effluent condenser inlet on the “one” dehydrator QLTsystem. The vacuum being generated by the eductor on the “one”dehydrator QLT system provides the energy to move the additional stillcolumn effluents to the inlet of the condenser. On some dehydrators, astill column effluent condenser is provided. Where a usable still columneffluent condenser is provided on a dehydrator to be retrofitted, theuncondensed vapors from the effluent condenser are collected byconnecting the vacuum generated by the “one” dehydrator eductor to theoutlet of the retrofitted dehydrators' effluent condenser.

In another embodiment, one eductor and one vacuum separator is used inthe combination QLT/VRSA unit. This embodiment comprises a vacuumchamber in the top of the emissions separator. One eductor is used tocreate the vacuum in the vacuum chamber. The VRSA flow line from theoutlet of the back-pressure regulator connects directly to the vacuumchamber with all other components and operation of the VRSA remainingthe same. The vacuum in the vacuum chamber is preferably maintained at 2to 3 inches of water column which is enough vacuum for both the QLT andVRSA processes.

A two or three phased liquid accumulation separator is installed in theline connected to the outlet of the dehydrator effluent condenser. Theseparator collects condensed liquids created by cooling the effluentsfrom the dehydrator still column. The uncondensed gases from thedehydrator effluents flow from the gas outlet of the liquid accumulationseparator to the vacuum chamber. The vacuum port of the eductor connectsto the vacuum chamber, and the collected uncondensed gases and anyunseparated hydrocarbon liquids from the QLT and VRSA processes flowthrough the eductor and are compressed to approximately 20 to 25 psig inthe lower chamber of the emissions separator.

As previously noted, the liquid accumulation separator can be two orthree-phased. A three-phased liquid accumulation separator separates thecondensed liquids into its hydrocarbon and water components. Thehydrocarbons and water are then be dumped to separate storages. Atwo-phased liquid accumulation separator also separates the condensedliquids into hydrocarbon and water components, but the condensedhydrocarbons are not be dumped directly to storage. Instead, thecondensed hydrocarbons flow with the uncondensed gases from the outletof the liquid accumulation separator and enter into the vacuum chamber.In the vacuum chamber, the condensed hydrocarbons mix with any liquidhydrocarbons from the VRSA process and flow with the collected gasesthrough the vacuum port of the eductor to be compressed into the lowerchamber of the emissions separator. The emissions separator isthree-phased to separate liquid hydrocarbons from glycol. Any liquidhydrocarbons collected in the emissions separator are dumped to storageby the three-phasing system of the emissions separator.

In one embodiment, the compressor used on the VRSA has an extendedcross-head system that connects the crank-shaft to the piston. Theextended cross-head system creates a chamber where the connecting rodruns through two sets of packing. The top set of packing prevents thecompressed gases from entering the cross-head chamber, and the lower setof packing prevents the compressor oil from entering the cross-headchamber. The cross-head chamber has a tapped and threaded opening to theatmosphere. Any gases or oil that might enter the cross-head chamber areordinarily released to the environment.

Because the VRSA creates a vacuum, the release of gases or oil from thecross-head chamber to the environment can be prevented by connecting thecross-head chamber to the VRSA vacuum chamber. A simple flow meter isinstalled in the line connecting the cross-head chamber to the vacuumchamber. Excess flow through the simple flow meter would indicate aproblem with either the upper or lower cross-head packing

The preceding examples can be repeated with similar success bysubstituting the generically or specifically described compositions,biomaterials, devices and/or operating conditions of this invention forthose used in the preceding examples.

Although the invention has been described in detail with particularreference to these preferred embodiments, other embodiments can achievethe same results. Variations and modifications of the present inventionwill be obvious to those skilled in the art and it is intended to coverall such modifications and equivalents. The entire disclosures of allreferences, applications, patents, and publications cited above, and ofthe corresponding application(s), are hereby incorporated by reference.

1. A method for preventing the release of natural gas at a natural gaswell processing system from being released to the atmosphere, the methodcomprising: collecting evolved gases from a storage tank; entraining theevolved gases into a fluid stream; compressing the evolved gases andfluid stream; sending the evolved gases and fluid stream to an emissionsseparator; and separating the gases from the fluid for furtherprocessing.
 2. The method of claim 1 further comprising collecting theevolved gases using a vacuum.
 3. The method of claim 2 furthercomprising providing an eductor to create the vacuum and to entrain thegasses into the liquid stream.
 4. The method of claim 1 furthercomprising mixing a first compressed gas with a second compressed gasflowing in a pipeline, the second compressed gas having a BTU lowerrelative to the BTU of the first compressed gas to prevent gaseoushydrocarbons in a natural gas well processing system from entering aliquid state.
 5. A method for preventing the release of gaseoushydrocarbons at a natural gas well processing system from entering theatmosphere, the method comprising: providing an emissions separator;sending to the emissions separator the entrained gases that evolve formhydrocarbon liquids when the liquids are separated from a flowing gasstream at higher pressure and put in the lower pressure of anintermediate separator; sending the gaseous hydrocarbons to a compressorand compressing the gaseous hydrocarbons; and sending the compressedgaseous hydrocarbons to a flowing gas stream for further processing orpoint of sale, compressing the gaseous.
 6. A natural gas well processingsystem comprising: a hydrocarbon storage tank; an eductor linked to saidstorage tank to receive gasses that evolve in the storage tank, entrainsaid gasses into a fluid stream and compress said gasses and said fluidstream; and an emissions separator linked to said eductor for receivingsaid evolved gases and fluid stream for separation of said gasses fromthe fluid stream and for sending said gasses out of said emissionsseparator for further processing.